Kuschall Champion Service Manual 0515
Contents
1. Components Backrest Rear wheel with handrim Quick release axle D Folding mechanism Nh Front wheel fork with front wheel D Footrest Ox Frame De Seat Mudguard Seat depth 540 480 mm in increments of 20 mm AL TI 400 460 mm in increments of 20 mm C Backrest angle 76 80 5 85 89 5 94 Knee to heel length 220 500 mm in increments of 10 mm AL Tl 300 340 400 500 mm in increments of 10 mm C Seat height front 450 540 mm stepless adjustable Seat height rear 590 490 mm stepless adjustable D Backrest height 500 465 mm in increments of 15 mm Total length 75 approx 825 1190 mm AL TI 90 approx 775 1140 mm AL TI 85 approx 800 1165 mm C Seat width 540 480 mm in increments of 20 mm D Total width Seat width plus 160 240 mm Total width folded approx 280 540 mm AL Aluminium TI Titanium C Carbon c k schall 6 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION FRAME FRAME The k schall Champion frame is available in aluminium titan or carbon Aluminium or titan frames are available with frame angles of 5 and 85 carbon frames with a frame angle of 85 Changing Frame Fitting frame tub2. Distance sleeves If additional side parts or another type of rear wheel is fitted or if the rear seat height is agjusted the distance between the rear wheels may have to be increased by fitting additional distance sleeves Distance sleeve assembly Difficulty OO Tools 522 wm C 19 M Remove rear wheel E Loosen and remove adapter sleeve B nut and washer D m Slide the distance sleeve A onto the thread of the adapter sleeve B M Secure the adapter sleeve to the adapter plate again using the nut and washer M The rear wheels must be subsequently adjusted until parallel Chap Rear wheels Adjustment of rear wheel parallelism D gt 55 Nm Adapterplate adjustment to folding unit or assembly of new adapter plate Difficulty eoo Tools 5 E Slightly loosen the two bolts 9 E If an option is mounted loosen nuts of the adaption holder gt Chap Antitipper Transit wheels Antitioper assembly M Move the adapter plate with both brackets B on the vertical tube into the desired position B Fix the adapter plate with the two bolts gt 15 Nm c k schall 29 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION BRAKES BRAKES Fitting adjusting the parking brake Difficulty eeo Tools 5 Following each positioning the rear wheel parking brakes e g when changing the wheel chamber must be reagjusted The parking brake function i
3. c k schall 17 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION FOOTRESTS FOOTRESTS Lower leg length UL To change the lower leg length the footrest can be fixed at a higher or lower position gt Chap Footrests Footrest height adjustment Short lower leg lengths UL can be set using a high mounted footrest Chap Footrests Footrest mounted in high position Aluminium frame UL220 ULS10 high mounted footrest ULS20 ULS90 standard footrest short frame ULAOO UL500 standard footrest long frame Titan frame UL220 ULS40 high mounted footrest ULS560 UL390 standard footrest short frame ULAOO ULS500 standard footrest long frame Carbon frame ULSOO ULSAO high mounted footrest UL400 UL500 standard footrest Possible footplate situations in relationship to seat angle and front wheel size Set to front Set to rear ST340 ST380 ST400 ST480 ST340 ST380 ST400 ST480 Seat angle S 4 5 ER 4 gt EN 4 5 3 4 5 0 mm v v v v v v v x x v x x 10 mm v v v v v v v v x v v x 20 mm v v v v v v v v x v v x N 30mm v v v v v v v v x v v x 40mm v v v v v v v v v v v x E 50 mm v v v v v v v v v v v v 60 mm v v v v v v v v v v v v 70 mm v v v v v v v v v v v v 30 mm v v x v v x x x x x x x 40 mm v v x v v x v x x x x x 5 50 mm v v v Y Y x Y x x Y x x S 60 mm v v v v v v v x x v x x 70 mm VIG e v i lv
4. 51 0 518 695 757 e Fax 51 0 518 695 758 e nederland invacare com e csede invacare com Norge Invacare AS Grensesvingen 9 e Postboks 62 50 Etterstad e N 060 Oslo Tel 47 0 22 57 95 00 Fax 47 0 22 57 95 01 e norway invacare com island invacare com sterreich Invacare Austria GmbH e Herzog Odilostrasse 101 e A 5310 Mondsee Tel 4 5 6252 5555 O e Fax 45 6252 5555 4 e info invacare austria com Portugal Invacare Lda Rua Estrada Velha 949 P 4465 84 Le a do Balio Tel 51 0 225 1059 46 47 Fax 551 0 225 1057 39 e portugal invacare com Sverige amp Suomi Invacare AB Fagerstagatan Oe 165 91 Sp nga Tel 46 0 8 761 70 90 e Fax 46 0 8 761 81 08 e swedenainvacare com e finland invacare com Schweiz Suisse Svizzera Invacare AG e Benkenstrasse 260 e CH 4108 Witterswil Tel 41 0 61 487 70 80 e Fax 41 0 61 487 70 81 e switzerland invacare com United Kingdom Invacare Limited Pencoed Technology Park Pencoed Bridgend CF35 5AQ e Switchboard Tel 44 0 1656 776 200 Fax 44 0 1656 776 201 e Customer services Tel 44 0 1656 776 222 Fax 44 0 1656 776 220 Australia nvacare Australia Pty Ltd e ABN 45 074 676 5 8 PO Box 5002 1 Lenton Place North Rocks NSW 2151 Australia e Freephone 1800 069 042 Fax 02 8859 5555 e E mail sales invacare com au e Web www invacare com au New Zealand Invacare New Zealand PO Box 62 124 4 Westfield Place Mt Wellington Au
5. M M 450 M M M M M M M M M 460 M M M M M M M M M 470 M M M M M M M M M 480 x x x x x x S S S 490 x x x x x x x x x Rear wheel 25 SHh Pos1 Pos2 Pos 3 Pos 4 Pos 5 Pos 6 Pos 7 Pos 8 Pos 9 390 XL XL XL XL XL XL XL XL XL 400 XL XL XL XL XL XL XL XL XL 410 XL XL XL XL XL XL XL XL XL 420 XL XL XL L L L L L L 430 XL XL L L L L L L L 440 L L L L L L L L L 450 L L L L L M M M M 460 L L L L M M M M M 470 L L M M M M M M M 480 M M M M M M M M M 490 x x M M M M M M M Rear wheel 26 SHh Posi Pos 2 Pos 3 Pos 4 Pos 5 Pos 6 Pos 7 Pos 8 Pos 9 390 XL XL XL 400 XL XL XL XL XL 410 XL XL XL XL XL XL 420 XL XL XL XL XL XL XL 430 XL XL XL XL XL XL XL 440 XL XL XL XL L L L L 450 XL XL XL L L L L L L 460 XL XL L L L L L L L 470 XL L L L L M M M 480 L L M M M M M 490 L M M M M M M c k schall 22 K schall AG Switzerland 2015 09 Service Manual SIDE PARTS Mud guard assembly Difficulty O Tools 3 5 4 10 X2 If replacing a clothes guard with a mudguard first remove the clothes guard and the bracket attached to the vertical brace EP Attach the bracket to the vertical brace with the screws and remount the rear wheels PJ Slightly loosen the two screws on the adjustment plate and move it along the mounting bracket until the mudguard is in position E The position of the mudguard can also be adjusted To do this loosen the bolts adjust
6. adhesive grease dust from the push handle tube SS Apply a thin layer of hair spray all over the surface of the push handle tube onto which the handle is to be slid B Apply a thin layer of hair spray to the inside of the handle Slide the new handle onto the push handle tube M Move the handle into the correct position grooves facing upwards If along handle has been fitted and this is to be replaced with a short one the push handle tube must be shortened by 55 mm The push handle tube must be replaced when switching from a short to a long handle lo c k schall 16 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION BACKREST Replacing foldable push handles Difficulty eoo Tools Hole punch pliers 6 mm 3 4 M Remove the old foldable push handle B Pull down the backrest cover on the telescopic tube until its hole is uncovered IMPORTANT e Make sure that the threaded insert part no 1580450 supplied with the new push handle is used for assembly B Place the threaded insert in the telescopic tube B Punch a hole through the backrest cover with a distance of 10 mm from the upper egde using hole punch pliers see graphic below B Slide the new foldable push handle amp onto the telescopic tube E Pull up the backrest cover until it covers completely the rear hole gt 7 Nm low strength in the pushhanale E Fix the folda
7. folding unit Difficulty oO Tools 5 The bolt of the scissor mechanism must be checked regularly for play A The scissor mechanism must open and close easily Check that the retaining rings B are sitting well replace if neccessary Adjusting the folding unit Difficulty O Tools 3 16 E Remove the end stop nut from bolt B Apply new thread locking adhesive on bolt M Screw the end stop nut completely on the bolt again but do not tighten E Adjust the end stop of the folding unit by tightening resp loosening the grub screw B Tighten the end stop nut E Carry out the same settings on both sides gt 15 Nm high strength Check that the scissor mechanism opens and closes easily Check the seat cover for sufficient tension in Unfolded condition of the wheelchair E If neccessary repeat the steps above until all settings are correct Adjustment screw O The screw in the folding unit has the aim to reduce play il Depending on the play the screw head is slightly above the Surface The screw is secured and cannot become loose N IMPORTANT Do not modify the screw as it can result in a less easy folding and unfolding of the wheelchair c k schall 10 K schall AG Switzerland 2015 09 Service Manual BACKREST BACKREST Tension adjustable backrest KUSCHALL CHAMPION IMPORTANT Risk of damage to the wheelchair A too tight band inst
8. front wheel Replacing a front wheel fork Checking and adjusting the castor angle Checking and agjusting the drift angle Shift supporter on the frame RER Rear wheels repositioning Wheel camber adapter sleeves Adjusting the removable axle Distance sleeves Adapterplate adjustment to folding unit or assembly of new adapter plate pps c Fitting adjusting the parking brake Antitipper Transit wheels Tipper aid Cane holder Fitting the pelvic belt c k schall 5 LO SS P Or OY K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION GENERAL Introduction This service manual is part of the instructions and contains the tech nical information for servicing configuring and repairing a k schall wheelchair WARNING Danger of accident and severe injuries If the wheelchair is improperly set it can cause accidents and severe injuries Changes to the wheelchair may only be carried out by the dealer To guarantee the required safety and reliability all wheelchairs must be comprehensively checked once a year In part assembly and agjustment require extensive experience For this reason the following assembly instructions have been split into three categories Requirement Symbol Easy technical understanding required eoo Intermediate specialist knowledge required 0 Difficult specialist wheelchair ass
9. the mudguard position as required and retighten the bolts B Tighten the screws B Carry out the setting on both sides E By tightening or loosening the screws you can adjust how easily the armrest can be pulled out or pushed in The distance between the mudguard and the wheel must be either 8 mm or gt 25 mm to prevent fingers from becoming caught between the wheel and the mudguard gt 15 Nm gt 4 Nm gt 7 Nm Mudguard size in relationship to rear seat height and rear wheel size 2 4 4 5 0 7 Mw manmi No Ke i O 3 N 4A No Oo Rear wheel size o 9 W Ti 3 n c k schall 25 K schall AG Switzerland 2015 09 Service Manual SIDE PARTS Assembling and adjusting the siderest Difficulty O Tools 3 4 10 X2 EP Attach the bracket to the seat module with the bolts and nuts PJ Slightly loosen the two screws B on the height adjustment bracket then move the siderest to the desired height B lighten the screws 9 B By tightening or loosening the screws you can adjust how easily the armrest can be pulled out or pushed in O A wheel camber requires that an additional set of distance plates be fitted between the adapter plate and the side profile 2 Chap Rear wheels Adapterplate spacer assembly 9 15 Nm 10 Nm with carbon frame gt 4Nm Assembling the tubular armrest E Mount the armrest holder wit
10. 05 540 530 520 510 500 490 480 470 460 450 SEN E BS EM NE SEN ES ES EM E d D D D D k SEM EM BM EM SEM EE BS BM S E SES ES ES EC E SES E SN E SEM EM EC BE SEM AS BM Front seat height SHv per frame size castor fork and front wheel Carbon frame 85 long frame SHv ST 40 48 mm 03 04 05 540 Y 530 C Y 520 Y A 510 v Y v 500 v Y A 490 v Y 4 480 v Y S 470 v v z 460 v v 450 Y Rear seat height SHh The following possibilities are available to adjust the rear seat height SHh Adjustment of the adapter plate to the folding unit 9 Chap Rear wheels Adapterplate adjustment to folding unit or assembly of new adapterplate Replacement of the rear wheel with a larger or smaller one i Ze It must be ensured that the rear wheels are parallel after changing the rear seat height If required they must be reagjusted Chap Rear wheels Adjustment of rear wheel parallelism It must be ensured that the the castor pins are vertical after changing the rear seat height If required they must be readjusted 2 Chap Front wheels Checking and adjusting the alignment of the supporters c k schall K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION SEAT Checking the
11. 60 CH 4108 Witterswil kueschall invacare com www kuschall com Service Manual KUSCHALL CHAMPION k schall distributors ENGLISH 2015 09 Belgium amp Luxemburg Invacare nv e Autobaan 22 e B 8210 Loppem Tel 52 0 50 83 10 10 e Fax 52 0 50 85 10 11 belgiumainvacare com Danmark Invacare A S Sdr Ringvej 57 e DK 2605 Br ndby Tel 45 0 56 90 OO OO e Fax 45 0 56 90 OO 01 e denmark invacare com Deutschland Invacare GmbH e Alemannenstra Se 10 D 88516 Isny Tel 49 0 75 62 7 OO O Fax 49 0 5 62 7 OO 66 kontaktainvacare com European Distributor Organisation Invacare Kleiststralge 49 D 52457 Porta Westfalica Tel 49 0 57 31 754 540 e Fax 49 0 5 51 754 541 edo invacare com Espa a Invacare SA c Areny sine Poligon Industrial de Celr E 17460 Celr Girona Tel 54 0 972 49 52 00 Fax 54 0 9 2 49 52 20 contactsp invacare com France Invacare Poirier SAS Route de St Roch F 57250 Fondettes Tel 55 0 2 47 62 64 66 Fax 55 0 2 47 42 12 24 e contactfr invacare com Ireland Invacare Ireland Ltd Unit 5 Seatown Business Campus e Seatown Road e Swords County Dublin Ireland Tel 555 1 810 7084 Fax 555 1 810 7085 ireland invacare com Italia Invacare Mecc San s r l e Via dei Pini 62 1 56016 Thiene VI Tel 59 0445 58 OO 59 e Fax 59 0445 58 00 54 e italiaainvacare com Nederland Invacare BV Celsiusstraat 46 e NL 6 16 BZ Ede Tel
12. Allen key is of good quality and not worn Torque Ov OX KUSCHALL CHAMPION Mm Allscrew connections must be tightened with the torques specified in the following instructions Checks Visual check M Check all components for cracks especially the areas around joints and welded seams Checking the screw connections E Check all bolts with the torques specified in the instructions regularly and adjust if required CAUTION Several screw connections have been secured with thread locking adhesive If these are opened they must be secured again using new thread locking adhesive Liquid high strength and low strength adhesives are available For torque entries notice shall be made whether an adhesive and which adhesive needs to be used Identifying and alleviating malfunctions Malfunction Possible cause Measure The wheelchair will not move in a straight line Incorrect tire pressure in a rear wheel Correct tire pressure One or more spokes broken Replace defective spoke s Spokes unevenly tensioned Tighten excessively loose spokes Dirty or damaged wheel bearings Clean or replace bearings Bearing block of castor fork is not vertical Align bearing block vertically Front wheels not set to the same height Position the front wheels in such a way that they touch the ground at the same time Rear wheels not parallel or axes not aligned Adjust the prestress load on the scis
13. S SSN SSS ANN SS SS WS SKS Ge Ge eh Se B 15Nm a A til SS SOS SSS XM J GK SS SS SSNS KN S ASS SS SAS SSS NN Es gt 10 Nm high strength K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION FRONT WHEELS Shift supporter on the frame Difficulty OO Tools 5 The supporter on the frame may be infinitely adjusted IMPORTANT Possible damage to the paint on the frame tube Be very careful when inserting the supporter in frame tube Bi Loosen the bolts 9 with the washers on the supporter Push the supporter into the required position Retighten screws with new adhesive and washers Tighten the bolts Wi with new adhesive and washers on the supporter amp gt 10 Nm high strength Perform the same setting on both sides c k schall 27 K schall AG Switzerland 2015 09 Service Manual REAR WHEELS REAR WHEELS Rear wheels repositioning O The chair will be more stable the further rearwards that the rear Il wheels are fitted There are 9 possible rear wheel positions adjustable via the mount ing position of the vertical brace Difficulty OO Tools 8 4 5 10 m Remove the bolts from slide of the vertical brace WM Slide the vertical brace on the side support to the desired position B Insert bolts in
14. Velcro straps Velcro copic mediate without straps with stabilisation stabilisation bar bar m e e o 465 XL L L M L S M L Tension adjustable backrest with rearset push handles height adjustable Teles Inter Velcro straps Velcro copic mediate without straps with tube tube stabilisation stabilisation mi RH bar bar mm 9 e E e E 530 gd ve L 2xS S possible 435 L 2xM S SM L 450 L 2xM S S4M L 465 XL L L L S S4 M L c k schall 12 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION BACKREST Tension adjustable backrest with push hanales height adjustable Push Backrest Velcro straps Velcro handle tube without straps with nm RH stabilisation bar stabilisation bar mm o E e 0 e 300 S L S4 M S 315 S L S4 M S 330 M E S4 M S not 345 M L 2xM M 2 possible 360 S M L 2xM M 375 M 2xM M 390 v M L 2xM M 405 L L Staxm S S amp L L Wei 420 L L S L S S L iL 435 L L S L S S L L 450 L L S L S M L L 465 L L M L S M L L c k schall 13 K schall AG Switzerland 2015 09 Service Manual BACKREST Backrest height RH In order to adjust the backrest heig
15. allation may cause damage to the backrest when unfolding the wheelchair Make sure that the backrest bands are only adjusted in unfolded condition of the wheelchair Tension adjustable backrest with push handles standard Push Inter Velcro straps Velcro handle mediate without stabili straps with tube sation bar stabilisation Im RH bar Imm 9 E e 4 e 500 S S L S M S 315 S S L S M S 330 S i L S M S not 345 S L L 2xM M possible 360 S L L 2xM M 375 S L L 2xM M 390 5 L L 2xM M 405 L L L S 2xM S S L L 420 L L L S L S S L L 455 L L L S L S S L L 450 L L D S L S M L L 465 E L L M L 5 M L L Tension adjustable backrest with foldable push handles teles Inter Velcro straps Velcro copic mediate without stabili straps with tube tube sation bar stabilisation Ii RH bar mm 9 e e E e 3500 S S L S M S 315 S S L S M S 330 S L L S M S 345 S L L 2xM M 360 5 L L 2xM M not 5375 S L L 2xM M possible 390 S L L 2xM M 405 L L L S 2xM L 420 L L L S L L 435 L L L S L L 450 L L L S L L 465 L L L M L L lt lt k schall L K schall AG Switzerland 2015 09 Service Manual BACKREST Tension adjustable backrest without push handles
16. ble push handle with screw and washer SS Check screws on both sides of the push handle and re tighten if necessary M Carry out the same steps for the other push handle s dr 10mm IMPORTANT Make sure that the folding force is approximately 5 N 0 5 kg cl IMPORTANT Fixing screw may only be used once Alternatively the screw can be cleaned remove old thread locking adhesive and reinstalled with new low strength thread locking adhesive d he retrofit of foldable push handles requires new tubing Stabilisation bar Stabilisation bar assembly Difficulty O Tools 83 58 X2 With a back height RH405 or larger it is possible to assemble a stabili sation bar to increase the rigidity of the backrest handles M Remove backrest cover amp push handles B and 10 cm backrest band or end band if no push handles are assembled m Assemble a 5 cm backrest band or end band with the screws to the push handles E Assemble the push handles B with bolts and nuts E Attach the clamps together with the RH socket D and the LH socket with the screws below the backrest band to the push handles M Replace the push handle backrest band socket assembly M Press pin D and slide the stabilisation bar D into the RH socket then swing the stabilisation bar upwards press pin D and click the stabilisation bar into the LH socket amp gt 4Nm O gt 7 Nm D gt 4 Nm
17. both sides and secure it at the desired height using the clamp bolt B Secure the end band or the standard backrest cover to the backrest tube on both sides using the screws Height adjustable rear set push handles These push handles can only be used in combination with adjustable backrests not with standard backrests Difficulty eeo Tools 3 8 X2 B Fit the intermediate tube on both sides using the bolts B B Slide the backrest bands corresponding to the desired backrest height RH onto the intermediate tube X B Fit the telescopic tube corresponding to the desired backrest height RH on both sides using the bolt B Slide the holder D and the sleeve onto the telescopic tube D and secure it using the screws 9 For the minimum backrest height the holder of the rear set push handle must be fitted to the intermediate tube In this case the gt Nm sleeve is not required Nm B Slide the end band D onto the telescopic tube and secure it on both sides using the screws QD gt 15 Nm D gt 4Nm Replacing the handle An adhesive e g hair spray is used in these instructions When applied to the handle this substance works as a lubricant and as an adhesive once dry After drying the adhesive used must be able to resist a pull off force of 750 N If in doubt contact Kuschall AG Difficulty eeo M Remove the old handle M Remove any residue residual
18. ckland New Zealand e Freephone 8000 468 222 Freefax 0800 807 788 E mail sales invacare co nz e Web www invacare co nz K schall AG Switzerland 2015 09 1588992 B
19. e lf a pelvic belt is fitted add the washer D m Fit the clothes guard D using the bolt present and any additional washer to the backrest joint gt 13 Nm 10 Nm with carbon frame gt Nm 3 15Nm Function control H Fold and unfold the backrest this must be done easily Make sure the y clothes guards are positioned slightly higher than the rear wheels K Check that the clothes guards flip up easily e Clothguard sizes in relationship to rear seat heightm rear wheel size and mounting position of the vertical brace Rear wheel 22 SHh Posi Pos2 Pos 3 Pos 4 Pos 5 Pos 6 Pos7 Pos 8 Pos 9 3590 M M M M M M M M M 400 M M M M M M M M M 410 M M M M M M M M M 420 M M M S S S S S S 430 M S 5 5 S 5 5 S S 440 5 S S S S 3 S S S 450 x x x S S 5 S 5 460 x x x x x x x x x 470 x x x x x x x x x 480 x x x x x x x x x 490 x x x x x x x x x c k schall 21 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION SIDE PARTS Rear wheel 24 SHh Posi Pos2 Pos 3 Pos 4 Pos 5 Pos 6 Pos 7 Pos 8 Pos 9 E L L L L L L L L L L L L L L L L L L L L L L L L L M M M M L L L M M M M M M 440 M M M M M M M
20. embly knowledge eee and experience required The required tools and their respective sizes are listed above each instruction The instructions include information on the torques with which the respective screw connections must be tightened Adhering to the given torques requires the use of a torque spanner Tools Symbol Allen key 2x3 4 5 6 Phillips screwdriver x 2 Straddle spanner 19 11 Socket spanner ring spanner C 8 10 14 22 Spare parts and adaptations All spare parts can be purchased from k schall s Customer Services An electronic spare parts catalog is available by logging onto www kuschall com Only original spare parts may be used Installing additional adaptations to a k schall wheelchair requires the prior written approval of K schall AG Tightening Allen screws Allen keys are not designed for greater forces When tightening or loosening an Allen screw it is therefore advisable to apply force to the nut to prevent the hexagon socket from being damaged Tightening and loosening B Turn the nut with a socket spanner only use a straddle spanner if there is insufficient space and merely hold the screw tight with the Allen key c k schall 4 K schall AG Switzerland 2015 09 Service Manual Tightening and loosening if there is no nut If an Allen screw is directly screwed into a screw thread the screw must be tightened using an Allen key O Ensure that the
21. es Difficulty OO Tools 4 510 B Fit both frame tubes into the side supporters using bolts B and tighten lightly gt 15 Nm 10 Nm with carbon frame Attaching the side supporters frame tubes and seat cover Difficulty OO Tools 5 510 O he purpose of the threaded connection through the frame il mounting holes is to provide additional fixing The frame is thus easier to guide and is better secured Any misalignment of the toe angle of the front wheels is counteracted E Attach the side supporters frame tubes seat cover and optionally the holders for siderests using bolts D through the frame mounting holes on both sides and tighten D gt 13 Nm 10 Nm with carbon frame c k schall 7 K schall AG Switzerland 2015 09 Service Manual SEAT SEAT Fitting seat cover to frame KUSCHALL CHAMPION Difficulty OO Tools 3 4 510 E Fit seat cover to side supports and frame on both sides using bolts and 9 gt 15 Nm 10 Nm with carbon frame 5Nm Front seat height SHv The following possibilities are available to adjust the front seat height SHv Replace the front wheel with a larger or smaller one 2 Chap Front wheels Replacing a front wheel Replace the front fork with a larger or smaller one gt Chap Front wheels Replacing a front wheel fork Move the side support on the frame gt Chap Front wheels Shift sup
22. h countersunk screws and 5 washers and cap nuts on the side supporter M Place the armrest clamp part sleeve to the 5rd hole from above inside the armrest tube B B urn the cylinder head bolt through the smaller hole of the armrest tube completely into the armrest clamp part a sleeve M Secure the cylinder head bolt with sleeve and securing cap nut from the other side O If the folding mechanism affects the armrest tube ll when folding the wheelchair sleeve D must be displaced downwards Em Mount the tube plugs and the armrest pad E Place the armrest in the holder OQ Nm gt Nm high strength c k schall 24 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION FRONT WHEELS FRONT WHEELS Replacing a front wheel Difficulty eoo Tools 2x3 bl Remove the screw with disk on one side Remove the wheel axle B Si Remove the front wheel Place the sleeves D between the new front wheel and the fork E Slide the axle through the fork sleeves and the front wheel and fix the axle using the screw Here use the new screw supplied with the wheel as this screw comes with a thread locking device Function check The wheel may not wobble but must rotate easily Replacing a front wheel fork Difficulty O Tools west 10 Em Remove the bolt with the washer Mm Remove the front wheel fork E Check the bearing distance r
23. ht RH the backrest tubes have to be fixed in a different position or they have to be exchanged Standard backrest cover height adjustment Difficulty oo Tools 3 58 Push the backrest cover so that bolt and nut on the backrest tube are revealed Remove bolt and nut 3 Adjust the backrest tube B to the required height then insert the screw into the closest hole and tighten it again Carry out the same setting on both sides Reposition the backrest cover correctly Tension adjustable back height adjustment Difficulty OO Tools 83 58 M Remove the backrest cover 9 E Slide the backrest straps either up or down to locate the fixing bolt E Remove bolt and nut B B Adjust the backrest tube to the required height then insert the screw B into the closest hole and tighten it again M Carry out the same setting on both sides M Reposition the backrest cover O Inthe case of major changes of the backrest height RH bands ul may have to be inserted or removed and a larger smaller backrest cover may be necessary c k schall 14 K schall AG Switzerland 2015 09 Service Manual BACKREST Backrest angle RW Backrest angle adjustment Difficulty O Tools 4 510 M Remove the lower bolt from the side supporter B and move the backrest to the required position The spacer D remaines fixed in the latch bolt B insert bolt and nut amp into the cl
24. hten in the desired position with adjusting screws QD m Adjust the rear wheel parallelism gt Chap Rear wheels Adjustment of rear wheel parallelism Length adjustment M Press the spring pin Slide the inner part of the antitipper to the required position until the spring pin locates in the correct hole O Optionally antitippers can be mounted with pre attached transit ll wheels M shown in graphic Transit wheels require a pre drilled antitioper tube Antitipper tubes with pre attached transit wheels can be orderd from k schall AG WARNING Risk of tilting When choosing antitippers with transit wheels make sure to have them installed on both sides of the wheelchair O To remove the antitipper press button and slide it downwards il out of the holder Function control The distance between the antitipper and the ground must be 40 60 mm It must be easy to fold up the antitipper Tip the wheelchair back wards using the antitioper until the axle is perpendicular to the antitipper s point of contact with the ground In this position the distance between the rear wheel and the ground must be at least 50 mm X x z5O0 mm c k schall 31 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION OPTIONS amp ACCESSORIES Tipper aid Cane holder Tipper aid and cane holder assembly adjustment Difficulty O Tools 10 There are 5 options available which are assemb
25. ing and circlip D and replace if required m Insert the new front wheel fork with the washer and the bolt and tighten the bolt m Assemble the front wheel gt Chap Front wheels Replacing a front wheel M Carry out the function check see below Function check Tip the wheelchair backwards by 90 so that it is lying on the backrest and the rear wheels Turn the fork upwards position A and let it tip downwards The fork has been correctly adjusted if it easily turns to beyond the bottommost point and remains there position B If the fork turns back to the lower position position C it has not been sufficiently tightened There is a risk that the front wheels will start to wobble at high speeds c k schall 25 K schall AG Switzerland 2015 09 Service Manual FRONT WHEELS Checking and adjusting the castor angle Difficulty OO Tools 90 angle Triangle ruler or similar est 10 5 M Place the wheelchair on a plane surface B Turn the castor wheel transversely to the rear wheels M Apply a 90 ruler on the castor wheel and check if it is in a 100 vertical position to the floor It shows immediately whether the castor is in 90 to the floor or not If there is a gap between the ruler and the castor on the upper or lower rim of the wheel it clearly indicates that the castor angle is not 90 In the graphic to the right the gap amp on the upper part of the castor whee
26. isv s 80 mm v v v v v v v v x v x x 90 mm v v v v v v v v x v v x 100 mm Y v v v v v v v v v v x If the knee to heel length is smaller than seat height front SHv mi nus 100 mm there are no conflicts possible between footplate and Castors c k schall 18 K schall AG Switzerland 2015 09 Service Manual FOOTRESTS Footrest height adjustment Difficulty OO Tools 4 58 M Remove on both sides bolt and nut amp which fix the telescopic tube to the frame B Extend the footrest telescope to the required length then insert the bolts into the closest holes M Carry out the same setting on both sides SS Tighten the locking bolts a on both sides Function control Check that the footrest is firmly attached but that it can fold easily Footplate Footplate replacement Difficulty OO Tools 84 58 Remove the screws and the screws B Remove the footplate O and replace it by the new one E Attach the footplate with the screws and the screws B Function control Check that the footrest is firmly attached but that it can fold easily Fitting the footplate set to the front The footplate is fitted set back as standard Difficulty O Tools 94 5 M Remove the screws and the screws B E Remove the screws and washers on both sides E Rotate the footplate mounting by 180 The elongated
27. kdschall designed for life KUSCHALL CHAMPION DEALER Keep this manua L S g M l C The procedures in this manual MUST be performed by a e rvi ce a n u d qualified technician 2014 K schall AG All rights reserved Republication duplication or modification in whole or in part is prohibited without prior written permission from K schall AG Trademarks are identified by and All trademarks are owned by or licensed to K schall AG or its subsidiaries unless otherwise noted Service Manual TABLE OF CONTENTS GENERA c Introduction Spare parts and adaptations Tightening Allen screws Torque Checks Identifying and alleviating malfunctions OVERVIEW Components Dimensions Fitting seat cover to frame Front seat height SHv Rear seat height SHh Checking the folding unit Adjusting the folding unit BACKREST M Tension adjustable backrest Backrest height RH Backrest angle RW Push handles backrest telescopes Replacing foldable push handles Stabilisation bar OT ES KE Lower leg length UL Footplate Ee 5 qpoe c Clothes guard assembly Mud guard assembly Assembling and adjusting the siderest Assembling the tubular armrest FRONT el Replacing a
28. l shows that the fork is set too much to the rear If the gap would be on the lower part the fork would be set too much to the front i SS If the castor wheel is not vertical loosen bolts B E Adjust the castor angle with screw until the wheel is 100 parallel to the vertical side of the ruler E Re tighten bolts E Perform the same adjustment on both sides Checking and adjusting the drift angle Difficulty OO Tools 90 angle Triangle ruler or similar 5 M Place the wheelchair on a plane surface O The drift angle is measured the same way as the castor angle il For this adjustment the castor wheel has to be turned in driving direction parallel to the rear wheels E Turn the castor wheel in driving direction parallel to the rear wheels SS Apply a 90 ruler on the castor wheel and check if it is in a 100 vertical position to the floor m ifthe castor wheel is not vertical unscrew the bolts B with washers on the supporter IMPORTANT Possible damage to the paint on the frame tube Be very careful when turning the supporter around the frame tube SS lurn the supporter in or outside until the castor wheel is parallel to the vertical side of the ruler E Retighten bolts with new adhesive and washers E Perform the same adjustment on both sides c k schall 26 WGKA GG Ge KUSCHALL CHAMPION 72277 I WGKA LY ofp iffy SSSAMAQAAQA DQ NNNNS S
29. led adjusted equally Tipper aid with cane holder Cane holder Tipper aid Mm Attach the adaption holder amp onto the bracket B using the two nuts and washers E Slide the tipper aid tube into the daption holder and fasten it with the spring clip For cane holder option E Remove the screw from the backrest cover then replace it together with the strap Q O The cane holder can also be repositioned on the tube gt 13 Nm Function control The tipper aid cane holder may not touch the floor if the wheelchair is tipped backwards B f the tipper aid cane holder touches the floor remove it and change the position of the spring clip This is done by removing the tube end cap then pushing the spring clip B one hole further into the tube using a screwdriver Fitting the pelvic belt Difficulty OO Tools Plastic hammer 9 5 10 m Fit the steel strap with the bolt on both sides of the side profile B pressing the upper part of the steel strap inwards e g using a plastic hammer Ensure that the webbing of the pelvic belt is not twisted during Ah assembly and the locking mechanism shows towards the front Ensure that the seat cover does not get caught between the steel X strap and the side supporters during assembly 7 13Nm c k schall ER K schall AG Switzerland 2015 09 c x K schall designed for life ad K schall AG Benkenstrasse 2
30. new position and tighten the nuts E Carry out the same setting on both sides Wheel camber adapter sleeves 1 adapter sleeves or 3 adapter sleeves B can be used The wheel camber changes accordingly The rear wheels must subsequently be adjusted until parallel Adjustment of rear wheel parallelism Difficulty eee Tools 22 wm C 19 m Measure the distance between the front and rear wheels at axle level If this distance is not the same x y B Loosen the adapter sleeve nut m Use the open end spanner to rotate and adjust the adapter Sleeves on both sides so that the distance between the front and rear wheels at axle level is identical x y Bl Re tighten the adapter sleeve nut Adjusting the removable axle Difficulty O Tools est 11 19 m Remove the rear wheel SS Hold the end of the removable axle using the straddle spanner m Adjust the length L of the removable axle by turning the nut The length is correctly adjusted if the removable axle engages correctly when fixing the wheel and wheel has just minimal clearance O he wheels must be exchanged left to right side and vice versa il after adjusting both removable axles The adjustment must now be checked or carried out again to ensure the wheels can be switched c k schall 28 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION REAR WHEELS
31. osest hole and tighten it again M Carry out the same setting on both sides Function control The backrest must fold easily and the ratchet bolt must sit tightly against the side supporter Push handles backrest telescopes Push handle telescopic tube replacement Difficulty O Tools 85 58 X2 B Remove the backrest cover 9 M Remove the screws holding the uppermost backrest band or standard backrest cover to the push handles or telescopic tubes B Slide the backrest straps or standard backrest cover either up or down to locate the fixing bolt E Remove bolts and nuts on both sides D M Remove push handles or telescopic tubes M Slide new push handle through backrest band B and fix it on the backrest with bolt D E Fix the upmost backrest band B or standard backrest cover with screws E Carry out the same setting on both sides M Reposition the backrest cover correctly c k schall 15 K schall AG Switzerland 2015 09 Service Manual BACKREST Height adjustable integrated push handles Difficulty eeo Tools 3 58 X2 B Fit the backrest tube 9 corresponding to the desired backrest height RH on both sides using the bolts B B Slide the backrest bands corresponding to the desired backrest height RH and if required the end band or the standard backrest cover over the backrest tube X B Slide the push handle B into the backrest tube on
32. porter on the frame i lo After adjusting the front seat height the verticality of the castor pins Adjusting the front seat height changes the seat angle It may be necessary to adjust the rear seat height correspondingly It must be ensured that the rear wheels are parallel after changing the front seat height If required they must be reagjusted Chap Rear wheels Adjustment of rear wheel parallelism need to be checked and adjusted if neccessary gt Chap Front wheels Checking and adjusting the alignment of the supporters Front seat height SHv per frame size castor fork and front wheel SHv mm Aluminium Titan frame 75 long frame short frame ST 40 48 ST 54 58 ST 40 48 ST 54 58 03 03 04 O v 04 05 o o5 540 550 520 510 500 490 480 470 460 450 SE E E EM E d D D D DK d D D D D k SE EM EM EM SE E E EM NE SEM E E BM S D O D A E SE A EM A AS AS E lt lt k schall K schall AG Switzerland 2015 09 Service Manual SEAT KUSCHALL CHAMPION Front seat height SHv per frame size castor fork and front wheel SHv mm Aluminium Titan frame 85 long frame short frame ST 40 48 ST 54 58 ST 40 48 ST 54 58 03 O A 03 o o e 03 o 05 03 o
33. s only guaranteed if the tire has the corresponding air pressure M Check that the rear wheels have sufficient air SR Loosely fix the clamping piece to the frame with the screw A Si Slide the brake into the correct position and tighten the Screw A O When the brake is on the brake shoe D must press approx 4 mm ll into the tire Furthermore please note that very little force is required for amp 15 Nm 10 Nm with carbon frame activating and deactivating the brake If necessary a brake lever extension can be fitted Jo Visual control Check that the parking brake is correctly positioned The brake is correctly adjusted if the brake shoe does not press more than 4 mm into the tire when the brake is on Function control Place the loaded wheelchair on a ramp with a 7 slope with the par king brake on The wheelchair must not move Carry out this check with the wheelchair both facing down the ramp and facing up the ramp c k schall 50 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION OPTIONS amp ACCESSORIES Antitipper Transit wheels Antitipper assembly Difficulty O Tools 3 5 6 22 wmmC 19 O gt 55 Nm M Remove adapter sleeve nut and washer gt 15 Nm E Mount the antitipper with the adapter sleeve nut D and S washer B sleeve D and the screw to the clamping part Qp4Nm m Adjust the angle of the antitipper and tig
34. side of the footplate mounting D is now pointing forwards B Fit the footplate mounting again using the screws and washers M Secure the footplate using the screws and the screws B B Set the desired footplate angle and tighten the screws gt Chap Footrests Angle adjustment of the footplate Function control Check that the footrest is firmly attached but that it can fold easily c k schall 19 A gt 7Nm B gt 7 Nm K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION FOOTRESTS Angle adjustment of the footplate Difficulty OO Tools 6 4 5 58 E Slightly loosen the bolts under the footplate which secure the telescopic tube B to the footplate mounting B Set the footplate to the desired angle B lighten the bolt on both sides Function control Check that the footplate can fold easily B lo adjust the folding ability of the footplate tighten resp loosen nut on the underside of the footplate c k schall 20 K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION SIDE PARTS SIDE PARTS Clothes guard assembly Difficulty O Tools 4 10 EK Attach the fixation piece with bolt and nut and screw to the frame E Align the clothes guard to the rear wheel and note the best hole on the clothes guard to fix it to the backrest hinge Si Remove the bolt from the backrest joint IMPORTANT
35. sor mechanism and or the trail The wheelchair tips backwards too easily Rear wheels have been fitted too far forward Fit rear wheels further back Backrest angle too great Reduce backrest angle Seat angle too great Mount the adapter plate lower on the side profile Mount the smaller castor fork The brakes engage poorly or asymmetrically Incorrect tire pressure in one or both rear wheels Correct tire pressure Brake setting incorrect Correct brake setting Roll resistance is too great The front wheels wobble when moving fast Insufficient tire pressure in the rear wheels Correct tire pressure Rear wheels are not parallel Insufficient tension in the front wheel bearings block Ensure that the rear wheels are parallel Lightly tighten the nut in the bearings block axle Front wheel is worn flat Replace front wheel The front wheel is stiff or stuck Dirty or damaged bearings Clean or replace the bearings The wheelchair is very difficult to unfold The backrestcover is too tight Loosen the backrestbands a little Handling seems imprecise The scissor mechanism is not closed properly If required remove dirt from scissor mechanism The scissor mechanism is misaligned Realign the scissor mechanism c k schall K schall AG Switzerland 2015 09 Service Manual KUSCHALL CHAMPION OVERVIEW OVERVIEW
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